富康 维修手册 英文版.docx

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1、富康 维修手册 英文版 THE BOOKCitroen ZX Service and Repair ManualMark CoombsModels coveredAll Citroen ZX Hatchback models with petrol engines, including special/limited editions 1360 cc, 1580 cc, 1761 cc, 1905 cc and 1998 cc (inc. 16-valve)Covers most features of Estate models Also covers 1124 cc engine Does

2、 not cover Diesel engine models (1881-320-10X1)? Haynes Publishing 1996 A book in the Haynes Service and Repair Manual Series All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any

3、information storage or retrieval system, without permission in writing from the copyright holder. ISBN 1 85960 149 9 British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library.Printed by J H Haynes & Co Ltd, Sparkford, Nr Yeovil, Somerset B

4、A22 7JJ, England Haynes Publishing Sparkford, Nr Yeovil, Somerset BA22 7JJ, England Haynes North America, Inc 861 Lawrence Drive, Newbury Park, California 91320, USA Editions Haynes S.A. 147/149, rue Saint Honore, 75001 PARIS, France Haynes Publishing Nordiska AB Box 1504, 751 45 UPPSALA, SwedenRage

5、 Bad 2022, 2022 ContentsLIVING WITH YOUR CITROEN ZXIntroduction Safety First! General dimensions and weights Page Page Page 0?4 0?5 0?6MOT Test ChecksChecks carried out from the drivers seat Checks carried out with the vehicle on the ground Checks carried out with the vehicle raised Checks carried o

6、ut on your vehicles exhaust emission system Page Page Page Page 0?7 0?8 0?9 0?10Roadside RepairsBuying spare parts and vehicle identification numbers Jacking, towing and wheel changing Booster battery (jump) starting Identifying leaks Radio/cassette unit anti-theft system - precaution Conversion fac

7、tors Page Page Page Page Page Page 0?11 0?12 0?14 0?15 0?15 0?16Routine MaintenanceRoutine maintenance and servicing Lubricants, fluids and capacities Maintenance schedule Weekly checks Every 6000 miles or 6 months Every 12 000 miles or 12 months Every 18 000 miles or 18 months Every 24 000 miles or

8、 2 years Every 40 000 miles or 2 years Every 48 000 miles Every 72 000 miles Page Page Page Page Page Page Page Page Page Page Page 1?1 1 ?2 1 ?3 1 ?8 1?11 1?14 1?20 1?22 1?23 1?26 1?26 ContentsREPAIRS & OVERHAULEngine and Associated SystemsTU series engine in-car repair procedures XU series engine

9、in-car repair procedures Engine removal and general engine overhaul procedures Cooling, heating and ventilation systems Fuel and exhaust systems - carburettor models Fuel and exhaust systems - single-point fuel injection models Fuel and exhaust systems - multi-point fuel injection models Emission co

10、ntrol systems Engine electrical systems Page 2A?1 Page 2B?1 Page 2C?1 Page Page 3?1 4A?1Page 4B?1 Page 4C?1 Page 4D?1 Page 5?1TransmissionClutch Manual transmission Automatic transmission Driveshafts Page Page Page 6?1 7A?1 8?1 Page 7B?1BrakesBraking system Page 9?1SuspensionSuspension and steering

11、Page 10?1Body EquipmentBodywork and fittings Page 11?1ElectricalBody electrical systems Wiring Diagrams Page 12?1 Page 12?19REFERENCETools and Working Facilities General Repair Procedures Fault Finding Glossary of Technical Terms Page REF? 1 Page REF? 4 Page REF? 5 Page REF?12IndexPageREF?16 0?4Intr

12、oductionIntroduction to the Citroen ZXThe Citroen ZX range was introduced to the UK in June 1991. Originally, the ZX was available with a choice of 1.1 litre (1124 cc), 1.4 litre (1360 cc), 1.6 litre (1580 cc) or 1.9 litre (1905 cc) engines. Not all engine sizes, however, were available in all marke

13、ts (the 1.1 litre version was not available in the UK). At first, only five-door Hatchback models were available. All models have a five-speed manual transmission as standard; a fourspeed automatic transmission was offered as an option on 1.6 and 1.9 litre models. All engines are derived from the we

14、llproven TU series (1124 cc and 1360 cc) and XU series (1580 cc and 1905 cc models) engines, which have appeared in many Citroen and Peugeot vehicles. The engines are of four-cylinder overhead camshaft design, mounted transversely and inclined to the rear, with the transmission mounted on the left-h

15、and side. In late 1992, a three-door Hatchback variant was introduced. At the same time, three new sports models were also introduced, all of which were equipped with new engines. These new models were the 1.8 litre (1761 cc) Furio, the 2.0 litre (1998 cc 8-valve) Volcane, and the 2.0 litre (1998 cc

16、 16-valve) 16-valve model. All of these new models are available in three-door form only. All three of the new engines are again derived from the XU series engine. On all models, fully-independent front suspension is fitted, with the components attached to a subframe assembly. The rear suspension is

17、 semi-independent, with torsion bars and trailing arms. All models in the range are comprehensively-equipped, and anti-lock braking (ABS) and air conditioning systems are available as options on certain models (ABS is standard on the 2.0 litre 16-valve). Provided that regular servicing is carried ou

18、t in accordance with the manufacturers recommendations, the Citroen ZX should prove reliable and very economical. The engine compartment is well-designed, and most of the items requiring frequent attention are easily accessible.Citroen ZX 1.4 Reflex Plus 5-doorAcknowledgementsThanks are due to Champ

19、ion Spark Plug, who supplied the illustrations showing spark plug conditions. Certain other illustrations are the copyright of Citroen Cars Ltd, and are used with their permission. Thanks are also due to Sykes-Pickavant Limited, who provided some of the workshop tools, and to all those people at Spa

20、rkford who helped in the production of this manual.Project vehiclesCitroen ZX 2.0 16-valveVarious project vehicles were used in the preparation of this manual, and appear in many of the photographic sequences. These include a 1360 cc, 1580 cc, 1761 cc, 1905 cc, 1998 cc 8-valve and a 1998 cc 16-valve

21、 Safety First!Working on your car can be dangerous. This page shows just some of the potential risks and hazards, with the aim of creating a safety-conscious attitude.0?5General hazardsScalding? Dont remove the radiator or expansion tank cap while the engine is hot. ? Engine oil, automatic transmiss

22、ion fluid or power steering fluid may also be dangerously hot if the engine has recently been running.? Mains voltage is also dangerous. Make sure that any mains-operated equipment is correctly earthed. Mains power points should be protected by a residual current device (RCD) circuit breaker.Special

23、 hazardsHydrofluoric acid? This extremely corrosive acid is formed when certain types of synthetic rubber, found in some O-rings, oil seals, fuel hoses etc, are exposed to temperatures above 400C. The rubber changes into a charred or sticky substance containing the acid. Once formed, the acid remain

24、s dangerous for years. If it gets onto the skin, it may be necessary to amputate the limb concerned. ? When dealing with a vehicle which has suffered a fire, or with components salvaged from such a vehicle, wear protective gloves and discard them after use.Fume or gas intoxication? Exhaust fumes are

25、 poisonous; they often contain carbon monoxide, which is rapidly fatal if inhaled. Never run the engine in a confined space such as a garage with the doors shut. ? Fuel vapour is also poisonous, as are the vapours from some cleaning solvents and paint thinners.Burning? Beware of burns from the exhau

26、st system and from any part of the engine. Brake discs and drums can also be extremely hot immediately after use.The battery? Batteries contain sulphuric acid, which attacks clothing, eyes and skin. Take care when topping-up or carrying the battery. ? The hydrogen gas given off by the battery is hig

27、hly explosive. Never cause a spark or allow a naked light nearby. Be careful when connecting and disconnecting battery chargers or jump leads.Crushing? When working under or near a raised vehicle, always supplement the jack with axle stands, or use drive-on ramps. Never venture under a car which is

28、only supported by a jack. ? Take care if loosening or tightening hightorque nuts when the vehicle is on stands. Initial loosening and final tightening should be done with the wheels on the ground.Poisonous or irritant substances? Avoid skin contact with battery acid and with any fuel, fluid or lubri

29、cant, especially antifreeze, brake hydraulic fluid and Diesel fuel. Dont syphon them by mouth. If such a substance is swallowed or gets into the eyes, seek medical advice. ? Prolonged contact with used engine oil can cause skin cancer. Wear gloves or use a barrier cream if necessary. Change out of o

30、ilsoaked clothes and do not keep oily rags in your pocket. ? Air conditioning refrigerant forms a poisonous gas if exposed to a naked flame (including a cigarette). It can also cause skin burns on contact.Air bags? Air bags can cause injury if they go off accidentally. Take care when removing the st

31、eering wheel and/or facia. Special storage instructions may apply.Diesel injection equipment? Diesel injection pumps supply fuel at very high pressure. Take care when working on the fuel injectors and fuel pipes. Warning: Never expose the hands, face or any other part of the body to injector spray;

32、the fuel can penetrate the skin with potentially fatal results.Fire? Fuel is highly flammable; fuel vapour is explosive. ? Dont let fuel spill onto a hot engine. ? Do not smoke or allow naked lights (including pilot lights) anywhere near a vehicle being worked on. Also beware of creating sparks (ele

33、ctrically or by use of tools). ? Fuel vapour is heavier than air, so dont work on the fuel system with the vehicle over an inspection pit. ? Another cause of fire is an electrical overload or short-circuit. Take care when repairing or modifying the vehicle wiring. ? Keep a fire extinguisher handy, o

34、f a type suitable for use on fuel and electrical fires.Asbestos? Asbestos dust can cause cancer if inhaled or swallowed. Asbestos may be found in gaskets and in brake and clutch linings. When dealing with such components it is safest to assume that they contain asbestos.Remember.DO? Do use eye prote

35、ction when using power tools, and when working under the vehicle ? Do wear gloves or use barrier cream to protect your hands when necessary. ? Do get someone to check periodically that all is well when working alone on the vehicle, ? Do keep loose clothing and long hair well out of the way of moving

36、 mechanical parts. ? Do remove rings, wristwatch etc. before working on the vehicle - especially the electrical system. ? Do ensure that any lifting or lacking equipment has a safe working load rating adequate for the |ob.DONT? Dont attempt to lift a heavy component which may be beyond your capabili

37、ty - get assistance. ? Dont rush to finish a job, or take unverified short cuts. ? Dont use ill-fitting tools which may slip and cause injury. ? Dont leave tools or parts lying around where someone can trip over them. Mop up oil and fuel spills at once. ? Dont allow children or pets to play in or ne

38、ar a vehicle being worked on.Electric shock? Ignition HT voltage can be dangerous, especially to people with heart problems or a pacemaker. Dont work on or near the ignition system with the engine running or the ignition switched on. 0?6General Dimensions & WeightsDimensionsOverall length: Volcane,

39、Funo and 16-valve models All other models Overall width (excluding mirrors): Volcane and 16-valve models Funo models All other models Overall height Volcane, Funo and 16-valve models All other models Wheelbase - all models Front and rear track: Reflex and Avantage models All other models Turning cir

40、cle: Models with manual steering Models with power-assisted steering 4090 mm 4070 mm 1710 mm 1690 mm 1700 mm 1400 mm 1390 mm 2540 mm 1410 mm 1420 mm 10.5 m 10.7 mWeightsKerb weights (approximate): 1124 cc and 1360 cc models: Three-door models Five-door models 1580 cc models: Three-door models Five-d

41、oor models 1761 cc models: Three-door models Five-door models 1905 cc models: Three-door models Five-door models 1998 cc 8-valve models: Three-door models Five-door models 1998 cc 16-valve models Maximum gross vehicle weight: 1124 cc and 1360 cc models 1580 cc models 1761 cc models 1905 cc models 19

42、98 cc 8-valve models 1998 cc 16-valve models Maximum roof rack load Maximum towing nose weight Maximum towing weight: Braked trailer: 1905 cc and 1998 cc models All other models Unbraked trailer: 1124 cc and 1360 cc models 1580 cc models 1761 cc models 1905 cc models 1998 cc models 935 kg 945 kg 995

43、 kg 1015 kg 1008 kg 1024 kg 1055 kg 1085 kg 1060 kg 1091 kg 1150 kg 1490 kg 1540 kg 1550 kg 1570 kg 1600 kg 1630 kg 75 kg 70 kg1100 kg 1000 kg 470 490 500 510 530 kg kg kg kg kg MOT Test ChecksThis is a guide to getting your vehicle through the MOT test. Obviously it will not be possible to examine

44、the vehicle to the same standard as the professional MOT tester. However, working through the following checks will enable you to identify any problem areas before submitting the vehicle for the test. Where a testable component is in borderline condition, the tester has discretion in deciding whethe

45、r to pass or fail it. The basis of such discretion is whether the tester would be happy for a close relative or friend to use the vehicle with the component in that condition. If the vehicle presented is clean and evidently well cared for, the tester may be more inclined to pass a borderline compone

46、nt than if the vehicle is scruffy and apparently neglected. It has only been possible to summarise the test requirements here, based on the regulations in force at the time of printing. Test standards are becoming increasingly stringent, although there are some exemptions for older vehicles. For ful

47、l details obtain a copy of the Haynes publication Pass the MOT! (available from stockists of Haynes manuals). An assistant will be needed to help carry out some of these checks. The checks have been sub-divided into four categories, as follows:0?71Checks carried out FROM THE DRIVERS SEAT2Checks carr

48、ied out WITH THE VEHICLE ON THE GROUND3Checks carried out WITH THE VEHICLE RAISED AND THE WHEELS FREE TO TURN4Checks carried out on YOUR VEHICLES EXHAUST EMISSION SYSTEM1Checks carried out FROM THE DRIVERS SEATHandbrake? Test the operation of the handbrake. Excessive travel (too many clicks) indicat

49、es incorrect brake or cable adjustment. ? Check that the handbrake cannot be released by tapping the lever sideways. Check the security of the lever mountings.? Check that the brake pedal is secure and in good condition. Check also for signs of fluid leaks on the pedal, floor or carpets, which would indicate failed seals in the brake master cylinder. ? Check the s e r v o unit (when applicable) by operating the brake pedal several times, then keeping the pedal depressed and starting the engine. As the engine starts, the pedal will